Rod Connector System and Methods of Use

ABSTRACT

A rod connector is provided including a disc portion, a first shaft portion and a second shaft portion. The disc portion has a first side configured to engage a first rod and a second side configured to engage a second rod. The first shaft portion extends from the first side of the disc portion and includes threads along at least a portion of the length thereof for engaging threads of the first rod to draw the first rod into engagement with the disc portion. The second shaft portion extends from the second side of the disc portion and includes threads along at least a portion of the length thereof for engaging threads of the second rod to draw the second rod into engagement with the disc portion.

FIELD

This disclosure relates to connectors and, in particular, to connectorsfor joining rods together.

BACKGROUND

Many homeowners place curtain rods above windows to enable curtains tobe drawn open or closed over the window to selectively control theamount of light entering a room from outside the home. Curtains may alsobe drawn closed to inhibit those outside of the home from viewing insidethe home through the window. Curtain rods are also often used withshowers to hang a shower curtain along an opening to a shower to preventwater from exiting the shower.

Since the curtain rods must span the width of a window or the length ofa shower, the curtain rods can be very long. Even where telescoping rodsare used, the length of each rod may be very long. As a result, thecurtain rods are placed in long boxes for sale, storage, andtransportation. Long boxes are more costly to produce, to transport, andto store in a warehouse and consume too much display space in retailstores.

Further, connections can also provide a rough transition between tubes.In many instances, curtains are suspended from the rods using loops andhooks. The loops and hooks have to slide along the rods to open andclose the curtain. When there is a rough transition between the rods,the loops and hooks tend to hang up on the transitions as they slidealong the rods.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a rod connector according to a firstembodiment.

FIG. 2 is a top perspective view of a connecting disc of the rodconnector of FIG. 1 .

FIG. 3 is a side elevation view of the connecting disc of FIG. 2 .

FIG. 4 is a partial cutaway view of the rod connector of FIG. 1 .

FIG. 5 is a partial cutaway view of the rod connector of FIG. 1connecting two rods.

FIG. 6 is a front side elevation view of a rod connector according to asecond embodiment.

FIG. 7 is a right-side elevation view of the rod connector of FIG. 6 .

FIG. 8 is a cross-sectional view of an insert plug for use with the rodconnector of FIG. 6 .

FIG. 9 is a right-side view of the insert plug of FIG. 8 .

FIG. 10 is a partial cutaway view of the rod connector of FIG. 6 andinsert plugs of FIG. 8 connecting two rods.

FIG. 11 is a top perspective view of a rod connector according to athird embodiment.

DETAILED DESCRIPTION

A rod connector is provided for coaxially connecting two rods together.The rods may be curtain rods for supporting curtains over a window orshower rods for supporting a shower curtain. The rod connector also maybe used, for example, to connect rods used to support a shower caddy,rods of a storage support, and rods of a closet pole (e.g., for hangingclothes). Those having skill in the art will readily appreciate otherapplications where the rod connector may be used to join two rodstogether to increase the overall combined rod length. Use of the rodconnector enables two rods to be joined together to form a rod having anincreased length and smooth transition from one rod to the other. Thetwo rods may be separate when packaged enabling a box having a shorterlength to be used which reduces the costs of the box and costsassociated with shipping and storing the packaged rod system. The enduser or installer may join the two rods together using the rod connectorto provide a rod having a desired length, e.g., a length that spans thewidth of a window or the length of a shower.

The rod connector includes a disc portion that is positioned between theends of the two rods to be connected. The disc portion has a first sideconfigured to engage a first rod and a second side configured to engagea second rod. A first shaft portion extends from the first side of thedisc portion for connection with a first rod. The first shaft portionincludes threads along at least a portion of the length thereof forengaging threads within the first rod to draw the first rod intoengagement with the disc portion. A second shaft portion extends fromthe second side of the disc portion for connection with a second rod.The second shaft portion includes threads along at least a portion ofthe length thereof for engaging threads within the second rod to drawthe second rod into engagement with the disc portion. The first andsecond rods are connected to one another when the first and second rodsare threaded on to the first shaft portion and second shaft portion,respectively, such that the first and second rods engage the discportion. The disc portion creates a smooth transition from one rod toanother.

With respect to FIG. 1-5 , a rod connector 100 is shown according to afirst embodiment. The rod connector 100 includes a connecting disc 102and a stud 104. The connecting disc 102 includes a disc portion 106having a central opening 108 through which the stud 104 passes throughthe connecting disc 102. The stud 104 includes threads 110 disposedthereon for attachment to the rods 112, 114 as described in furtherdetail below. The stud 104 may be formed of a metal (e.g., steel). Asone example, the stud 104 has a diameter of 0.25 inches with 20 threadsper inch.

The central opening 108 of the connecting disc 102 may be sized to slideover the threads of the stud 104 along the length of the stud 104. Thecentral opening 108 may be sized such that the central opening 108 isslightly larger than the threads 110 of the stud 104 so that theconnecting disc 102 is maintained on the stud 104 by a friction fitconnection. The connecting disc 102 may be positioned at a middle pointof the stud 104 such that a first portion 104A of the stud 104 extendsfrom the connecting disc 102 in a first direction and a second portion104B of the stud 104 extends from the connecting disc 102 in a seconddirection opposite the first direction. As one example, the centralopening 108 may have a diameter of 0.25 inches.

The connecting disc 102 includes a collar 116 about the central opening108 on both sides of the connecting disc 102. The collars 116 increasesthe length of the central opening 108 through which the stud 104 passesthrough the connecting disc 102. The collars 116 may aid to stabilizethe connecting disc 102 and maintain the connecting disc 102 in aposition substantially perpendicular to the length of the stud 104. Thecollars 116 further increases the portion of the connecting disc 102that engages the stud 104 providing for increased frictional resistancebetween the connecting disc 102 and the stud 104.

In some forms, the central opening 108 of the connecting disc 102 mayinclude complementary threads for engaging the threads 110 of the stud104 to maintain the connecting disc 102 on the stud 104. The stud 104may be threaded into the connecting disc 102 until the connecting disc102 is at the desired position along the stud 104.

The disc portion 106 extends radially outward from the collar 116 to aradial outer edge or outer rim 118. The disc portion 106 issubstantially planar and forms a surface for the ends of tubes or rods112, 114 (see FIG. 5 ) to contact or abut when connected by the rodconnector 100. The outer rim 118 forms a flange 120 about the peripheraledge of the disc portion 106 on both sides of the connecting disc 102.Each flange 120 extends substantially parallel to the length of the stud104 to form recessed portions for receiving the rods 112, 114 therein.

In some embodiments, such as the embodiment in FIG. 11 , the flanges 120form a face against which the end of the rods 112, 114 engage. Forinstance, an outer portion of the flanges 120 may have an increasedradial thickness to provide a face 120A having a larger surface area forthe ends of the rods 112, 114 to engage when drawn toward the connectingdisc 102. In some forms, the flanges 120 form a surface extendingradially inward a substantial or the entire distance to the collars 116.In other forms, the outer diameter of the flange 120 may have the sameouter diameter of the rods 112, 114 so that the transition between therods 112, 114 over the flanges 120 of the connecting disc 102 is smooth.In further forms, the diameter of the flange 120 may be smaller orlarger than the outer diameter of the rods 112, 114.

The radial outer surface of the outer rim 118 is rounded or arcuate tocreate a smooth transition from the first rod 112 over the connectingdisc 102 and to the second rod 114. This smooth transitional surfacepermits or facilitates curtains and/or curtain rings or hooks whichsupport a curtain to pass from the first rod 112 to the second rod 114,and vice versa, without catching on an end of a rod or the connector 100as the curtains/curtain rings are drawn to one side or the other of thelength of the rods 112, 114. The connecting disc 102 may be formed of aplastic material, such as acrylonitrile butadiene styrene (ABS). Inother embodiments, the connecting disc 102 is formed of a metal material(e.g., steel, zinc, or aluminum). As one example, the outer diameter ofthe outer rim 118 is 0.905 inches and the inner diameter formed by theflange 120 is 0.875 inches.

With respect to FIG. 5 , the rod connector 100 is shown attaching tworods 112, 114 coaxially to one another. As shown, the rods 112, 114include attachment members or attachment plates 122, 124 positioned atthe end of the rods 112, 114. Each attachment plate 122, 124 includes athreaded hole (not shown). The attachment plate 122 is secured in theend of the rod using welding, indentations or any conventional methods.The first portion 104A of the stud 104 is threaded into the threadedhole of the attachment plate 122 until the end face 112A of the rod 112is brought into contact with the disc portion 106 of the connecting disc102 and within the flange 120. Likewise, the second portion 104B of thestud 104 is threaded into the threaded hole of the attachment plate 124until the end face 114A of the rod 114 is brought into contact with thedisc portion 106 and within the flange 120.

The outer diameter of the rods 112, 114 may be adjacent and in contactwith the radially inner surface of the flange 120. For example, the rods112, 114 may be ⅞ inch rods configured to be received within the flange120. The flange 120 spans the gap between the connecting disc 102 andthe rods 112, 114. As discussed above, due to the rounded or curvedshape of the outer rim 118 of the connecting disc 102, the outer rim 118creates a ramped or smooth transitional surface from the first rod 112to the second rod 114 when the rods 112, 114 are connected by the rodconnector 100 to permit curtains or curtain rings to pass over theconnection interface of the rods 112, 114 with ease.

By use of the rod connector 100, a curtain rod system may include twoshorter rods that are easily joined together by the rod connector 100 toform a longer rod upon assembly by the installer or end user. Thecurtain rod system with shorter rods may be contained, transported,stored, and displayed in a smaller box which reduces the costs of thebox, the cost to transport the system, the cost to store the system, andthe cost to display the system, all without compromising thefunctionality and utility of the curtain rod system.

With respect to FIGS. 6-10 , a rod connector system according to asecond embodiment is shown including a rod connector 200 and attachmentmembers or insert plugs 202. In this second embodiment, the insert plugs202 are positioned within the end of two rods that are to be connectedto one another. The rod connector 200 may thread into the insert plugs202 within each rod to coaxially connect the rods together.

With respect to FIGS. 6 and 7 , the rod connector 200 includes a discportion 204 positioned along a shaft 206. A first end 206A of the shaft206 may extend from the disc portion 204 in a first direction and asecond end 206B of the shaft 206 may extend from the disc portion 204 ina second direction opposite the first direction. As one example, the rodconnector 200 may have length of 2.188 inches.

In some forms, the rod connector 200 is a single piece with the shaft206 formed integrally or unitarily with the disc portion 204. Forexample, the rod connector 200 may be a molded or cast component. Therod connector 200 may be formed of a plastic or a metal material (e.g.,zinc). In other forms, the disc portion 204 includes a central openingthrough which the shaft 206 extends similar to that described above withregard to the first embodiment.

Each end 206A, 206B of the shaft 206 include threads 207 for engagingthe insert plugs 202 to secure two rods 222, 224 (see FIG. 10 ) togetheras described in further detail below. The threads 207 may extend alongthe entire length of the ends 206A, 206B of the shaft 206 or along aportion of the length of the ends 206A, 206B of the shaft 206 as shown.

The disc portion 204 may include a cylindrical body 208 coaxiallyaligned with the shaft 206. The disc portion 204 may include a ridge 210extending annularly about the body 208 and defining a first portion 208Aand a second portion 208B of the body 208. The cylindrical body 208 mayhave a diameter configured to be received within the end of the rods222, 224 when the rod connector 200 connects the two rods together, withthe ridge 210 having a diameter that is larger than the internaldiameter of the rods 222, 224. Thus, when connecting two rods together,the rods may extend over the body 208 and abut the ridge 210. As oneexample, the outer diameter of the cylindrical body 208 has a diameterof 0.6 inches and the outer diameter of the ridge 210 has an outerdiameter of 0.65 inches. The ridge 210 creates a smooth transitionbetween the two rods.

With respect to FIGS. 8-9 , the insert plugs 202 have a substantiallycylindrical body 211 having an outer diameter sized to be positionedwithin an end of a rod 222, 224 and be held within the rod 222, 224 by afriction fit. The outer diameter of the insert plugs 202 may be the samesize or slightly smaller than the internal diameter of the rods. Theinsert plugs 202 may be sized such that insertion into the rods 222, 224requires substantial force such that the insert plugs 202 are not ableto move substantially when the rod connector 100 is used to connect thetwo rods 222, 224 together. For example, the insert plug 202 may be heldin place by a frictional force that is greater than the forces expectedto be applied to the insert plug 202 under normal use and application ofthe rod connector system to prevent the insert plug 202 from movingsubstantially within the rod. Alternatively, indentations of the rod maybe dug into the body 211 to hold the insert plug 202 in place.

The insert plugs 202 include an internal surface 212 that defines acentral opening 214 for receiving the shaft 206 of the rod connector200. The insert plugs 202 include internal threads 216 along a portionor the entire length of the internal surface 212 for receiving andengaging the threads 207 of the rod connector 200.

The insert plugs 202 may be formed of a plastic such as acetal. In oneexample, the outer diameter of the insert plug 202 is 0.6 inches and theinsert plug 202 has a length of 0.8 inches.

In use, and with respect to FIG. 10 , one insert plug 202 is positionedwithin an end of a first rod 222 and a second insert plug 202 ispositioned within an end of a second rod 224. The threads 207 of eachend 206A, 206B of the shaft 206 of the rod connector 200 may be threadedinto the threads 216 of the insert plug 202. The rods 222, 224 may bethreaded on to the rod connector 200 simultaneously or one rod 222, 224at a time. The rods 222, 224 may be rotated until the respective ends222A, 224A of the rod abut or contact the ridge 210 of the disc portion204. The outer diameter of the rods 222, 224 may be the same or smallerthan the outer diameter of the ridge 210 such that the rods 222, 224 arenot able to pass beyond the ridge 210. The ridge 210 thus aids toprevent an installer from overtightening the rods 222, 224 on the rodconnector 200, which aids in limiting the force applied by the rodconnector 200 to the insert plugs 202 held in place by a friction fit.In one example, the rods 222, 224 have an outer diameter of 0.63 inches.

When the rods 222, 224 are connected via the rod connector 200, thefirst and second portions of the body 208A, 208B of the disc portion 204may be within the ends of the rods 222, 224. The outer diameter of thebody 208 may have a diameter that is the same or slightly smaller thanthe internal diameter of the rods 222, 224 such that the body 208engages the rods 222, 224 and aids to maintain the rods 222, 224 incoaxial alignment with one another. The ridge 210 of the disc portion204 may function similar to the outer rim 118 of the first embodiment,filling the gap between the rods 222, 224 such that a curtain and orcurtain hook may slide over the connection point without hooking orsnagging the rods 222, 224 or rod connector 200. In some forms, theouter edge of the ridge 210 is rounded or has an arcuate cross-sectionto form a smooth transitional surface to facilitate movement of acurtain or curtain hook across the connection interface of the rods 222,224. In some forms, the ridge 210 includes flanges extending over theends of the rods 222, 224 similar to the flange 120 of the connectingdisc 102 of the first embodiment.

Uses of singular terms such as “a,” “an,” are intended to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context. The terms “comprising,” “having,” “including,”and “containing” are to be construed as open-ended terms. It is intendedthat the phrase “at least one of” as used herein be interpreted in thedisjunctive sense. For example, the phrase “at least one of A and B” isintended to encompass A, B, or both A and B.

While there have been illustrated and described particular embodimentsof the present invention, those skilled in the art will recognize that awide variety of modifications, alterations, and combinations can be madewith respect to the above-described embodiments without departing fromthe scope of the invention, and that such modifications, alterations,and combinations are to be viewed as being within the ambit of theinventive concept.

What is claimed is:
 1. A rod connector comprising: a disc portion havinga first side configured to engage a first rod and a second sideconfigured to engage a second rod; a first shaft portion extending fromthe first side of the disc portion, the first shaft portion includingthreads along at least a portion of the length thereof for engagingthreads of the first rod to draw the first rod into engagement with thedisc portion; and a second shaft portion extending from the second sideof the disc portion, the second shaft portion including threads along atleast a portion of the length thereof for engaging threads of the secondrod to draw the second rod into engagement with the disc portion.
 2. Therod connector of claim 1 wherein the first side of the disc portionincludes a flange extending about a peripheral edge of the disc portionfor receiving an end of the first rod.
 3. The rod connector of claim 1wherein a radial outer edge of the disc portion is rounded.
 4. The rodconnector of claim 1 wherein the disc has an opening therethrough and ashaft extends through the opening of the disc, wherein the first shaftportion is a portion of the shaft on the first side of the disc and thesecond shaft portion is a portion of the shaft on the second side of thedisc.
 5. The rod connector of claim 4 wherein the disc further includesa collar about the opening on at least one of the first and second sidesof the disc portion.
 6. The rod connector of claim 1 wherein the discportion includes a ridge which an end of the first rod and an end of thesecond rod are drawn into contact with when connected via the rodconnector.
 7. The rod connector of claim 6 wherein the ridge spaces thefirst rod from the second rod when connected via the rod connector andforms a smooth transitional surface between the first rod and the secondrod.
 8. The rod connector of claim 6 wherein the disc portion includes asubstantially cylindrical body sized to be at least partially receivedwithin the first and second rods when the ends of the first and secondrods contact the ridge.
 9. The rod connector of claim 1 wherein thethreads of the first rod are internal threads of an attachment platesecured within the first rod and the threads of the second rod areinternal threads of an attachment plate secured within the second rod.10. The rod connector of claim 1 wherein the threads of the first rodare internal threads of an insert plug positioned within the first rodand the threads of the second rod are internal threads of an insert plugpositioned within the second rod.
 11. A rod connector comprising: a dischaving first side and a second side, the disc having an openingtherethrough; and a shaft extending through the opening of the disc suchthat a first portion of the shaft is on the first side of the disc and asecond portion of the shaft is on a second side of the disc, the shaftincluding threads disposed at least partially along the first portionand the second portion of the shaft, wherein the first portion of theshaft is configured to threadingly engage a threaded opening of anattachment member of the first rod to draw the first rod toward thefirst side of the disc and the second portion of the shaft is configuredto threadingly engage a threaded opening of an attachment member of thesecond rod to draw the second rod toward the second side of the disc.12. The rod connector of claim 11 wherein the first side of the discincludes a flange for receiving an end of the first rod and the secondside of the disc includes a flange for receiving an end of the secondrod.
 13. The rod connector of claim 11 wherein a peripheral edge of thedisc has a diameter that is greater than that of the first and secondrods, the peripheral edge being rounded and extending from the first rodto the second rod to provide a smooth transitional surface from thefirst rod to the second rod when the first and second rods are connectedvia the rod connector.
 14. The rod connector of claim 11 wherein thedisc further includes a collar about the opening on at least one of thefirst and second sides of the disc.
 15. The rod connector of claim 11wherein the attachment member of the first rod is a plate secured withinthe first rod.
 16. A rod connector system comprising: a rod connectorincluding a disc portion, a first shaft portion extending from a firstend of the disc portion, and a second shaft portion extending from asecond end of the disc portion, the first shaft portion includingthreads thereon and the second shaft portion including threads thereon;a first insert plug for insertion into an end of a first rod, the insertplug including a central opening for receiving the first shaft portionof the rod connector, the central opening including threads for engagingthe threads of the first shaft portion; and a second insert plug forinsertion into an end of a second rod, the insert plug including acentral opening for receiving the second shaft portion of the rodconnector, the central opening including threads for engaging thethreads of the second shaft portion.
 17. The rod connector system ofclaim 16 wherein the first insert plug has a substantially cylindricalbody sized such that upon insertion of the first insert plug into theend of the first rod, the first insert plug is held within the first rodby a friction fit.
 18. The rod connector system of claim 16 wherein thedisc portion includes a ridge which the ends of the first and secondrods engage when connected via the rod connector.
 19. The rod connectorsystem of claim 18 wherein the ridge spaces the first rod from thesecond rod and forms a smooth transitional surface between the first rodand the second rod.
 20. The rod connector system of claim 18 wherein thedisc portion includes a substantially cylindrical body sized to be atleast partially received within the first and second rods when the endsof the first and second rods contact the ridge.
 21. A method ofconnecting rods comprising: providing a rod connector including a discportion, a first shaft portion extending from a first side of the discportion, and a second shaft portion extending from a second side of thedisc portion, the first shaft portion including threads and the secondshaft portion including threads, threading the first shaft portion intoan attachment member of a first rod to draw the first rod toward thedisc portion; and threading the second shaft portion into an attachmentmember of a second rod to draw the second rod toward the disc portion.22. The method of 21 wherein the attachment members are insert plugshaving a threaded opening, the method further comprising inserting afirst insert plug into an end of the first rod and inserting a secondinsert plug into an end of the second rod.
 23. The method of claim 21wherein the first shaft portion and the second shaft portion are part ofa shaft extending through a central opening of the disc portion.